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1 100 Ohm, High Bandwidth, Ultra- Miniature Connectors, Cables and Accessories Series 80 High-Speed Featuring DuPont Teflon PFA Insulators Connectors United States United Kingdom Germany France Nordic Italy Spain Japan Sneak Peek Draft Edition September 2011

2 SERIES 801 HIGH SPEED FIELD HARDENED FOR GIGABIT THROUGHPUT THE RUGGEDIZED CIRCULAR CONNECTOR FOR HIGH BANDWIDTH FIELD APPLICATIONS Glenair Series 80 connectors are already deployed in countless tactical and field applications. In fact, the connector has become the industry standard for ruggedized environmental circular connectors in weight and size sensitive applications such as soldier gear, unmanned vehicles, and man-portable satellite uplink equipment. Now Glenair introduces its Series 80 solution for data bus frequencies above 1 GHz, such as are required for esata, 10GBASE-T, and LVDS systems. The Series 80 features all the same performance attributes as our original, but adds special purpose PFA (Teflon ) inserts that deliver superior insertion loss and balanced impedance performance for high-speed Ethernet applications at frequencies above 1 GHz. GLENAIR, INC Air Way Glendale, CA Tel: sales@glenair.com

3 Series 801 High-Speed Double-Start ACME Thread Connectors Table of Contents and Product Selection Guide Series 801 SERIES 801 HIGH-SPEED DOUBLE-START PRODUCT SELECTION GUIDE Introduction and General Reference Page 2 Introduction and General Reference Introductory materials covering high speed datalink protocols, connector product anatomy, contacts, tools, and space flight application mod codes. Plugs Page , Series 801 High-Speed Plugs These connectors are supplied with crimp contacts. Two shell styles are available: integral band platform for direct attachment of the cable shield, or choose accessory threads for attachment of backshells or strain reliefs. Crimp Receptacles Page , Series 801 High-Speed Crimp Receptacles Jam nut, square flange and in-line versions. Integral shield termination platform or accessory threads. are crimp-type, and are packaged with the connector. PCB/Solder Cup Receptacles Page Series 801 High-Speed Receptacles With Solder Cup or PCB Termination These panel mount connectors feature non-removeable contacts. Choose printed circuit board terminals or solder cup contacts. Terminations are potted with epoxy for additional protection. Overmolded Cordsets Page Differential Pair Cordsets Series 801 connectors are optimized for use with high frequency parallel pair cable. Glenair supplies this #28 AWG extruded FEP cable in either customer-specified lengths or preterminated to selected connectors. Metal Covers Page , Series 801 Metal Protective Covers Thread-on metal covers provide a watertight seal and prevent damage. Select nylon cord or wire rope lanyards with a range of ring terminal diameters to fit every application requirement. Rubber Covers Page , Series 801 Rubber Protective Covers Splashproof rubber covers are ideal for tactical applications. These friction-fit neoprene caps attach to cable or chassis with nylon rope. 1

4 Series 801 Introduction to High-Speed, Balanced Impedance Connectors and Cables for SATA and Other Differential Data Bus Applications High speed, High Bandwidth Performance for Military Grade Connectors and Cables I n response to requests for ruggedized, shielded connectors and cables to replace unshielded systems for high-speed serial data, Glenair developed its line of high speed serial data cordsets. Available for 100BASE-T, 1000BASE-T Gigabit Ethernet, IEE 1394, USB 2.0 and CAN Bus applications, these cordsets combined aerospacegrade data cables with Series 80 harsh environment connectors for maximum performance and minimum size. These cables, which used our standard Series 80 connectors with LCP insulators, have been successfully used in hundreds of Ethernet and other high speed data protocol applications. Now Glenair is proud to introduce our latest High-Speed innovation, a DuPont Teflon PFA Insulator equipped connector series that delivers even better impedance, VSWR and insertion loss performance in 100 Ohm, balanced impedance applications. Next-Generation Series 80 Connectors with DuPont Teflon PFA Insulators The new High-Speed connectors and ASAP cordsets presented in this catalog offer the same space and weight savings as our original LCP versions with superior performance in SATA and 2, 3, and 4 pair differential cable applications. These miniaturized connectors and cordsets are ideal for ultra high bandwidth data switches requiring high density packaging. Performance measurements for impedance, VSWR and insertion loss indicate that the special PFA (Teflon) insulator-equipped connectors, combined with our high-performance high-speed differential Series cable, deliver performance levels not available in other ultraminiature militarygrade interconnection assemblies. High-Speed Data Protocols Ethernet Performance Impedance VSWR 100 OHMS ±7 OHMS at 100-Picosecond <1.4 up to 4-GHz Insertion Loss 1 GHz.51 db 2 GHz.53 db 3 GHz.57 db 4 GHz 1.2 db 5 GHz 1.25 db Avionic and other military vehicle data transfer systems are growing increasingly complicated the number of data paths, data rates and the quantity and sophistication of subsystems continue to escalate. In addition to transmission speed, accuracy and reliability are tremendously important. Ethernet communication technology, with its huge installed base and history of reliability, is ideally suited for military vehicles and other field applications. Although there are many MIL-STD-1553 bus architecture and data link systems in use, applications such as tactical radar require faster data rates than older architectures can deliver. Basic Ethernet protocol is referred to as CSMA/ DC (Carrier Sense, Multiple Access and Collision Detection). To define some terms: Carrier Sense, the hosts can detect whether the medium is idle or busy; 2

5 Introduction to High-Speed, Balanced Impedance Connectors and Cables for SATA and Other Differential Data Bus Applications Series 801 Multiple Access, multiple hosts are connected to the common medium; and Collision Detection, when a host transmits, the protocols can determine whether its transmission has collided with the transmission of another host. If two or more information packets are sent simultaneously, a collision occurs and neither transmission is successful collision detection instructs the system to retransmit the colliding packets. Legacy Ethernet is half-duplex, meaning information can move in only one direction at a time, and is less-than-ideal for many avionic applications, as fastest-possible communication is not guaranteed. The collision problem occurs in any bus-oriented architecture, such as MIL-STD Full-duplex, switched Ethernet eliminates the collision problem by employing links that are pointto-point (not a bus) with a separate twisted pair for transmission and reception. Full-duplex also has the ability to send and receive data at the same time by employing a network of Ethernet switches able to forward incoming packets to their appropriate destinations. Gigabit Ethernet transfers data on four pairs of wires instead of only two pairs under legacy Ethernet forms. Further, transmission coding is enhanced for Gigabit Ethernet so that the standard clock rate of 125 MHz that produces 100 mbps data transfer rates in so-called Fast Ethernet is supercharged to 1,000 mbps. Gigabit Ethernet can fit an order of magnitude more data into the same cable than can Fast Ethernet, but employs the same transmission schemes and frame format as the earlier Ethernet versions. IEEE 1394 In the early 1990s, Apple Computer and Texas Instruments worked with the Institute of Electrical and Electronics Engineers (IEEE) to establish a very fast serial bus interface standard that supports data transfer rates of up to 400 mbps (in 1394a) and 800 mbps (in 1394b). Products supporting the 1394 standard go under different names, depending on the company. Apple uses the name FireWire, Texas Instrument uses Lynx and Sony uses i.link to describe their 1394 products. A single 1394 port can be used to connect up 63 external devices. In addition to its high speed, 1394 also supports isochronous data, delivering data at a guaranteed rate. This isochronous feature makes it ideal for devices that need to transfer high levels of data in real-time, such as video and audio applications makes full use of all SCSI (Small Computer System Interface, a parallel interface standard used for attaching peripheral devices to computers). 3

6 Introduction to High-Speed, Balanced Impedance Connectors and Cables for SATA and Other Differential Data Bus Applications MIL-STD-1553 MIL-STD-1553 defines all aspects of the serial digital multiplex data bus for military vehicles. Multiplexing combines two or more information channels on to a common transmission medium. When compared to older analog point-to-point wire bundles, multiplexing allows for weight reduction, simplicity of system design, standardization and flexibility. The 1553 data bus provides integrated, centralized system control and a standard interface for all interconnected equipment. Devices connect using twisted, shielded pairs of wires to maintain message integrity. All devices in the system are connected to a redundant pair of buses to provide a second path of traffic should one of the buses become damaged. Data rates of 1 megabit per second (mbps) are standard under MIL-STD MIL-STD-1773 contains the requirements for fiber optic cabling systems as a 1553 bus transmission medium. SATA Serial ATA (SATA or Serial Advanced Technology Attachment) is a computer bus interface for connecting host bus adapters to mass storage devices such as hard disk drives and optical drives. Serial ATA was designed to replace the older ATA (AT Attachment) standard (also known as EIDE), offering several advantages over the older parallel ATA (PATA) interface: reduced cable-bulk and cost (7 conductors versus 40), native hot swapping, faster data transfer through higher signalling rates, and more efficient transfer through an optional I/O queuing protocol. SATA is an emerging standard in C4ISR and other forms of battlefield communications and data transmission electronics. SATA host-adapters and devices communicate via a high-speed serial cable over two pairs of conductors..075 (1.9).015 (0.4).059 (1.5) 2x.038 (1.0).113 (2.9).097 (2.5) Conductor Insulation Inner Shield Outer Shield Jacket Cross-section of Glenair high-performance series Ohm differential parallel pair cable. For SATA applications Glenair recommends our cordsets with two parallel pairs of the special wire terminated to four #23 AWG contacts. Series Cable Construction Details Conductor Insulation Inner Shield Outer Shield Jacket Series Cable Properties Impedance 100 ± 10 Ohms Capacitance V.O.P. 80% Attenuation 28 AWG Silver Plated High Strength Copper Alloy Extruded Foamed Fluoropolymer Color: Blue and White Aluminum/Polyester Tape, 100% Coverage Round Silver Plated Copper Braid, 90% Coverage Extruded FEP Color: Transparent Blue Temperature Rating 12.0 pf/ft (Nom) MHz MHz MHz 150 C 4

7 Introduction to High-Speed, Balanced Impedance Connectors and Cables for SATA and Other Differential Data Bus Applications Series 801 High-Performance, High-Speed Differential Technologies Available Now From Glenair Series 80 Connectors with DuPont Teflon PFA Insulators The Series 80 is Glenair's latest entry in our world of high-speed interconnect solutions. The connector is equipped with special PFA (Teflon) insulators and is optimized for use with high-speed differential wire such as our series cable. Three insert arrangements are offered with 4, 7 and 10 size #23 contacts. The high-density, small form factor connector is suited for applications where traditional military circular connectors are too large or too heavy, and where the demands for high bandwidth, balanced impedance performance are at their highest. Other Glenair Solutions include: High-Bandwidth Fiber Optic Connectors, Cables, and Termini From our QPL MIL-PRF fiber optic connectors to our MIL-DTL type solutions, Glenair produces advanced performance fiber optic interconnection systems for every military and commercial standard. Fiber optic connectors, termini and cabling deliver secure high speed data in applications that require superior insertion loss and high data throughput. Fiber optic interconnect systems offer exponentially larger bandwidth compared to standard electrical cabling. Glenair manufactures a solution for every branch of the military and every mission-critical commercial application. Series #16 AWG fiber optic solutions are also now available. High-Performance Shielded Contact Connectors High-speed differential impedance contacts, such as those used in advanced digital communications applications, are another key specialty at Glenair. Our Twinax and Quadrax contacts are exactingly engineered and manufactured using the best available materials and manufacturing processes. Conductive elements are gold-plated copper alloy. Dielectrics are high performance fluorocarbon. Most Glenair cylindrical connectors, including our D38999 type, can accommodate shielded contacts that deliver balanced impedance performance for application frequencies above 1GHz.. Field-Ready, Integrated RJ-45 and USB Connectors Glenair integrates commercial connection devices that traditionally deliver datalinks for high-speed protocols into standard MS type connector shells. We offer rugged field-ready circular connectors that enclose single and double RJ-45 or USB connectors. Users of these standard products need not worry about damaging delicate high bandwidth connections in harsh conditions when these connectors are deployed in place of standard, non-protected solutions. The MIL-DTL-5015 or MIL-DTL type connector shells provide impact resistance, ingress protection and positive coupling. 5

8 Series 801 Series 801 High-Speed Cutaway View Beryllium Copper Retention Clip Fluorosilicone Grommet Plug G Load Anti- Decoupling Spring Machined Aluminum or Stainless Steel DuPont Teflon PFA Insulator Gold-Plated Pin Fluorosilicone Interfacial Seal Integral Shield Attachment Platform or Accessory Thread Peripheral Seal Fluorosilicone O-Ring Jam Nut Receptacle M39029 Type Split-Tine Socket Contact with Stainless Steel Hood Closed Entry DuPont Teflon PFA Insulator 6

9 Size #23 Crimp for Series 801 High-Speed Connectors Series 801 Size #23 Crimp Standard size #23 contacts accept #22 to #28 AWG wire. Choose "small bore" versions for #26 to #30 AWG wire. For thermocouple applications, specify alumel or chromel contacts. are bulk packaged. Terminate with standard M22520 crimper with special positioner. #23 Pin Contact Contact Type Wire Size Material Part Number Ø A Color Band Tool Code In. mm. Pin #22 #28 BeCu None A, C Pin #26 #30 BeCu Blue A, D Pin #22 #28 Alumel A None A, C Pin #22 #28 Chromel C None A, C Socket #22 #28 BeCu None A, C Socket #26 #30 BeCu Blue A, D Socket #22 #28 Alumel A None A, C Socket #22 #28 Chromel C None A, C #23 Socket Contact.289 (7.34).283 (7.19).165 (4.19).160 (4.06) Ø.048 (1.22).044 (1.12) Ø.0275 (0.699).0265 (0.673) HOOD.034 (0.86).029 (0.74) SPHERICAL RADIUS.015 (0.38) MAX FLAT.440 (11.18) MAX Ø A COLOR BAND Ø.056 (1.42) MAX COLOR BAND Ø.048 (1.22).044 (1.12) Ø.053 (1.35) MAX.275 (6.99).265 (6.73).031 (0.79).025 (0.64) Ø A.055 (1.40) MAX CRIMP TENSILE STRENGTH Values are in pounds and are minimums. Wire Gage Silver or Tin Coated Copper Wire Nickel Coated Copper Wire # # # # # Material and Finish Beryllium copper alloy per ASTM B196 or B197, 50 microinches gold plated per ASTM B488 Type II Code C Class 1.25 over nickel plate per QQ-N-290 Class 2, microinches. Thermocouple contacts: alumel or chromel alloy, unplated, per ANSI 96.1 Socket contact hood: stainless steel, passivated per AMS-QQ-P-35. Specifications Current Rating: 5 Amps maximum Voltage Drop (at 5 Amps and 25 C): 70 millivolts maximum Temperature Range: -65 to C Socket Contact Minimum Separation Force: 0.5 ounces Crimp Tools and Insertion/Removal Tools Crimper: Positioner: (standard). Use P/N for small bore contacts and Standard Insertion/Removal Tool:

10 Series 801 Size #23 Crimp Contact Termination, Installation and Removal Instructions for Series 801 High-Speed Connectors How To Terminate, Install and Remove Size #23 1 Set Up Crimp Tool. Install proper positioner into crimp tool. The label on the positioner shows the proper tool setting for each wire size. Turn the adjustment wheel to the correct setting. 2 Strip Wire. Remove wire insulation, taking care to avoid nicking or cutting wire strands. Strip wire to length shown. 3 4 Insert wire into contact. The wire should be visible in the inspection hole. Insert contact into crimp tool as shown. Make sure that the contact is fully inserted into the tool. Squeeze handle completely. The ratchet mechanism will not allow a partial crimp. Release handle and remove contact. Crimp Tool INSPECTION HOLE 3 1 Adjustment Wheel Positioner 2.145/.155 (3.68/3.94) 5 Inspect crimped contact. Wire should be fully inserted and the crimp should be uniform in appearance. 4 Insertion Extraction Tool EXTRACTION TIP WHITE END INSERTION TIP BLUE END Install contact into connector. Push the contact through the rear grommet until the contact locks into place. This can usually be done by hand without the need for a tool. If the wire gage is #26 or smaller, a tool is helpful. There are two techniques for installing contacts with a tool. One method is to push the contact in by hand, then use the tool to finish the insertion. The other method is to position the insertion tip against the contact shoulder, then insert the contact. Use insertion/extraction tool to install contacts. Slide the wire into the groove on the blue end of the tool. Slide the tool tip up the contact until it touches the contact shoulder. USE CARE TO AVOID DAMAGING THE CONNECTOR. 5 6 RUBBER GROMMET CONTACT RETAINER CLIP RETAINER TINE 7 Contact Extraction. Use tool The white end is used for contact extraction. First, push the wire into the groove of the metal tip. Slide the tip of the tool into the connector. Push the tool into the connector cavity until the tip bottoms in the connector. Avoid wiggling or rocking the tip. This may damage the cavity. A straight push is best. Pinch the wire between your finger and the white plastic grip and slide the tool and contact out of the connector. Wire insulation diameter greater than inches (1.14mm) is too large to work properly with the extraction tool. connector damage is possible. 7 RUBBER GROMMET 8

11 Size #23 Crimp Contact Sealing Plugs and Tools for Series 801 High-Speed Connectors Series 801 Grommet Sealing Plugs SEALING PLUG UNWIRED CONTACT Grommet sealing plugs are used to seal unwired contact cavities. The size #23 sealing plug is specially designed to fit Glenair Series 80 grommets. After installing unwired contacts into unused cavities, insert knob end of sealing plug into grommet until it bottoms against the unwired contact per illustration. Install sealing plugs with standard contact insertion/extraction tools. The size #23 plug is polyphenylsulphone. B Ø C Ø A D Part Military Part Insertion/ A Ref. B Ref. C Ref. D Ref. Size Color Number Number Removal Tool in. mm. in. mm. in. mm. in. mm. #23 Black (None) M81969/ Miniature Adjustable Crimp Tools Standard M22520/2-01 crimper for use with standard size #23 contacts. Crimp tools perform precision eight indent crimps for gas-tight wire terminations and excellent tensile strength. Adjustment wheel has 8 settings. Ratchet mechanism prevents improper crimps. Use with bayonet-type positioners. Check calibration with M22520/3 gages. Length is 6.75 inches, weight is approx. 10 oz. Military Part Daniels Part Part Number Number Number Tool Code M22520/2-01 AFM8 A Positioners For Use With Miniature Adjustable Crimp Tools C D These bayonet-type positioners hold contacts at correct height for crimping with M22520/2 type miniature step adjustable tools, above. Face plate shows correct tool settings. "C" Positioner is for standard size #23 contacts. #22-#28 AWG. Use with crimp tool. "D" Positioner is for small bore size #23 contacts. #26-#30 AWG. Use with crimp tool. Figure Part Number Military Part Number Daniels Part Number C (none) K1461 C D (none) (none) D Tool Code Contact Insertion and Removal Tool Insertion/Extraction Tool for #23. This tool features molded plastic grips and sturdy stainless steel tips. Blue/White molded handle. Military Part Daniels Part Size Type Part Number Number Number #23 Insertion/Extraction (None) (None) 9

12 Series 801 Series 80 High-Speed Guidelines for Space-Grade Applications Series 80 Connectors for Space Flight The small size and reduced weight of the Series 80 connector make it an excellent choice for space instrumentation. Series 80 connectors are available with special screening and outgassing for satellites and space vehicles. This section explains NASA guideline for connector selection, screening and outgassing. This section also explains how to order connectors screened to meet NASA EEE-INST-002. Five questions this section will answer regarding Series 80 connectors for space flight 1Material Selection: What materials are approved for space-grade connectors? What materials are prohibited? Does the Series 80 connector contain space-approved materials? Outgassing: What is 2 outgassing, why is it important, and how does it affect connector selection? Is special processing required to meet outgassing requirements? 3Screening: What is NASA screening and what level of screening is required? 4Magnetic permeability: Are nonmagnetic connectors required? 5Cryogenic exposure: Are these connectors suitable for -200 C. exposure? HOW TO ORDER SPACE GRADE SERIES 80 CONNECTORS Step 1: Find a Standard Part Number Electroless nickel plated shells are preferred for space fl ight. Cadmium plating is prohibited. Step 2: Select a NASA Screening Level The term Screening Level refers to the fi nal inspection procedure. Level 1 for mission-critical highest reliability Level 2 for high reliability Level 3 for standard reliability Step 3: Choose Outgassing Processing A detailed explanation of outgassing is on the following pages. The fl uorosilicone rubber seals commonly used on aerospace-grade connectors such as MIL- DTL and Series 80 connectors, along with certain bonding agents and inks, do not meet NASA outgassing requirements unless the connector is specially processed. Glenair outgassing tests have shown oven baking or thermal vacuum outgassing processing are suffi cient to reduce outgassing levels to NASA standards. Oven baking is more economical than thermal vacuum outgassing. Step 4: Select the Mod 429 Code that Matches the Desired Level of Screening and Outgassing Use the following table to choose the right modifi cation code. Add the mod code to the connector part number. Example: M6-7PA-429C NASA SCREENING LEVELS AND MODIFICATION CODES NASA Screening Level Level 1 Highest Reliability Level 2 High Reliability Level 3 Standard Reliability Special Screening Only Special Screening Plus Outgassing Processing 8 Hour Oven Bake 400 F. Thermal Vacuum Outgassing 24 hrs. 125 C. Mod 429B Mod 429J Mod 429C Mod 429 Mod 429K Mod 429A (Use standard part number) Mod 186 Mod 186M 10

13 Series 80 High-Speed Guidelines for Space-Grade Applications Series 801 Series 80 Connectors for Space Flight Material Selection: What 1 materials are approved for space flight? What materials are restricted? How to choose the right materials for Series 80 connectors. What materials are approved for space flight? Section C2 Connectors and of NASA EEE-INST-002 provides guidelines for materials used in connectors for space flight applications. Aluminum is a preferred material for connector components, and electroless nickel is the preferred finish. Beryllium copper is a preferred material for contacts. 50 microinch minimum gold plating is the preferred contact finish. LCP is a preferred material for dielectric insulating materials. What materials are prohibited? 100% tin plating shall not be used. Pure tin can grow whiskers which can lead to catastrophic electrical short circuits. Silver plating is prohibited because of corrosion concerns. Cadmium is prohibited because it is unstable in vacuum environments. Specifying Series 80 connectors for space flight Standard Series 80 connectors meet NASA guidelines for material selection. Specify M for aluminum shells with electroless nickel finish. The table below lists the Series 80 materials. SERIES 80 CONNECTOR MATERIALS APPROVED FOR SPACE FLIGHT Component Material Notes Shells, Coupling Nuts, Jam Nuts Aluminum alloy 6061 T6, electroless nickel plated Approved for Space Flight Rigid Insulators DuPont Tefl on PFA Approved for Space Flight Contact Retention Clip Beryllium copper, heat-treated, unplated Approved for Space Flight Grommet, Peripheral Seal, Interfacial Seal, O-ring Blended fl uorosilicone/silicone elastomer, 30% silicone per ZZ-R-765, 70% fluorosilicone per MIL-R Requires outgassing processing Hermetic Insert Vitreous glass Approved for Space Flight Pin Contact Pin Contact, Hermetic Socket Contact Beryllium copper alloy per ASTM B197, 50 microinches gold plated per ASTM B488 Type II Code C Class 1.25 over nickel plate per QQ-N-290 Class 2, microinches Nickel-iron alloy per ASTM F30 (Alloy 52),50 microinches gold plated per ASTM B488 Type II Code C Class 1.25 over nickel plate per QQ-N-290 Class 2, microinches Beryllium copper alloy per ASTM B197, 50 microinches gold plated per ASTM B488 Type II Code C Class 1.25 over nickel plate per QQ-N-290 Class 2, microinches. Approved for Space Flight Ferromagnetic material. Approved for Space Flight Socket Contact Hood Stainless steel, passivated per AMS-QQ-P-35 Approved for Space Flight Adhesives Potting Compound, PCB and Solder Cup Versions RTV and epoxies (see following table for outgassing info) Environmental and Hermetic Connectors: Stycast 2651/Catalyst 9 epoxy encapsulant. Filter Connectors: Stycast 2850FT/Catalyst 11 thermally conductive epoxy encapsulant. Requires outgassing processing Approved for Space Flight Filter Element Multilayer Ceramic Planar Array, ferrite inductors Approved for Space Flight 11

14 Series 801 Series 80 High-Speed Guidelines for Space-Grade Applications Outgassing: What is 2 outgassing and how does it affect connector selection? Is special processing required to meet outgassing requirements? What is outgassing? Plastic and rubber materials give off gaseous molecules. For example, the smell inside a new car is caused by polymer outgassing. Heat and vacuum increase the rate of diffusion. In a spacecraft the gases coming off polymers can contaminate optical surfaces and instruments. The result is degraded performance. How is outgassing measured? The space industry has adopted a standardized test procedure, ASTM E 595, to evaluate out-gassing properties of polymers. Small samples of material are heated to 125 C. at a vacuum of 5 X 10-5 torr for 24 hours. Then the sample is weighed to calculate the Total Mass Loss (TML). The TML cannot exceed 1.00% of the total initial mass. During the test, outgassed matter condenses on a cooled collector plate. The quantity of outgassed matter is caluclated to determine the Collected Volatile Condensable Material (CVCM). The CVCM cannot exceed 0.10% of the original specimen mass. Is special outgassing processing necessary on Series 80 connectors? NASA states A bakeout for outgassing control is driven by the application and may be required where tight contamination control must be maintained. NASA generally recommends that military circular connectors undergo outgassing processing. This processing can be performed by Glenair; however, some customers prefer to fabricate higher level subassemblies before outgassing processing. Outgassing At-a-Glance 1Fluorosilicone rubber components and encapsulants exceed NASA outgassing limits. 2NASA recommends outgassing processing to reduce outgassing to acceptable levels. 3An inexpensive oven bakeout has better results than the more costly thermal vacuum outgassing. The higher temperature of the oven bakeout is more effective at removing volatile materials. However, both methods assure compliance with outgassing limits. 4Glenair Mod 429 codes provide an easy ordering solution, whatever the outgassing option. OUTGASSING PROPERTIES OF MATERIALS USED IN SERIES 80 CONNECTORS TML TCVML Component Material % % Test Reference Front and Rear Insulator Liquid Crystal Polymer Vectra C NASA Test # GSC17478 Rear Grommet Interfacial Seal Peripheral Seal Front-To-Rear Insulator Bonding Material Insulator-to-Rubber Bonding Material Blended fl ourosilicone/silicone elastomer, 30% silicone per ZZ-R-765, 70% fl ourosilicone per MIL-R Eccobond 104 A/B Glenair testing conducted at NuSil Technology 02/27/2001 Emerson & Cuming Data Sheet DC3145 RTV, per MIL-A NASA Test GSC28621 Coupling Nut Retainer Torlon 4203L Glenair Test at NuSil Technology Coupling Nut Epoxy Hysol C Glenair Test O-Ring Flourosilicone Rubber NASA Test GSFC8687 White Epoxy Ink for Silkscreening Markem 7224 White NASA Test #GSC19899 Potting Compound, Solder Cup and PC Tail Connectors Hysol C Glenair Test Potting Compound, Solder Cup and PC Tail Connectors DC3145 RTV, per MIL-A NASA Test GSC28621 Potting Compound, Filter Receptacles Stycast epoxy, 2850FT/Catalyst Mfgr Data Sheet 12

15 Series 80 High-Speed Guidelines for Space-Grade Applications Series 801 3Screening: What is NASA screening and what level of screening is required? What is NASA screening? NASA specification EEE-INST-002 provides instructions on selecting, screening and qualifying parts for use on NASA GSFC space flight projects. Table 2A in the NASA specification contains inspection instructions for circular connectors including MIL-DTL Series 80 connectors are not mentioned in the NASA spec but are similar to D38999 connectors, so Table 2A applies by similarity to Series 80 connectors. What screening level is required? NASA defines three levels of screening: level 1 for highest reliability, level 2 for high reliability, and level 3 for standard reliability. Level 3 equates to standard lot acceptance inspection. Levels 1 and 2 call for additional testing. What about qualification requirements? Projects using connectors covered by military specifications are typically able to waive qualification testing. Projects considering using the Series 80 for space flight should obtain guidance from the NASA EEE-INST-002 SCREENING REQUIREMENTS Inspection/ Test overseeing space agency regarding the suitability of existing Glenair Series 80 test data, available on request. 4Magnetic permeability: Are nonmagnetic connectors required? Spacecraft designers generally avoid the use of ferromagnetic materials, which can become magnetized and can interfere with sensitive instruments. Series 80 aluminum shell connectors have a maximum permeability of 2 mu. NASA Level 1 NASA Level 2 Visual Inspection 100% 100% Mechanical 2 pcs. 2 pcs. Voltage (DWV) 2 pcs. 2 pcs. Insulation Resistance 2 pcs. 2 pcs. Contact Engagement and Separation Force (socket contacts) 2 pcs. N/A Coupling Force 2 pcs. N/A Air leakage (Hermetic connectors only) 100% 100% Solderability/Resistance to Soldering Heat 2 pcs. N/A 1. NASA screening requirements from Table 2A of EEE-INST-002 Screening Requirements for Circular Connectors... 5Cryogenic exposure: Can Series 80 connectors operate satisfactorily at -200 C? Series 80 connectors are rated to -65 C. Glenair does not have data to validate these connectors for cryogenic applications. EEE- INST-002 states...experience has proven it is possible for (non-certified) connector types to be used successfully at cryogenic temperatures. It is recommended that connector samples should be subjected to 5 cycles of cryogenic temperature...(followed by examination for cracks and DWV). SERIES 80 MODIFICATION CODES Modification Code Description Application Notes Part Number Example MOD-186 MOD-429 Oven bake connector for 8 hours at 400 F. Special NASA high-reliability screening and processing Intended for space fl ight applications. See Guidelines for Space-Grade Applications. Use this mod code on all Series 80 connectors. See Guidelines for Space- Grade Applications M5-3SN M13-37PB-429J MOD-489 Solder dip PC tails in 63/37 tin-lead M7-10PA-489 MOD-501 MOD-518 Replace spanner-style jam nut w/ hex-style jam nut w/ safety wire holes Waterblock sealing of PCB and solder cup receptacles. Sealing meets 10-4 cc/second maximum helium leak rate at 15 PSI pressure differential following three cycles of thermal shock. Use this mod code on all Series 80 rear panel mount jam nut connectors (style 07). For use on all panel mount receptacles with printed circuit board or solder cup contacts M6-4SN M9-19SA

16 Series 801 Series 801 High-Speed Double-Start ACME Thread Connectors General information INTEGRAL SHIELD TERMINATION AND MOLDING PLATFORM DOUBLE-START ACME MATING THREADS Double-Start ACME Thread with anti-decoupling spring or ratchet Special Purpose PFA (Teflon) Insulators Crimp Rear Release Integral Band Platform M39029 TYPE GOLD PLATED CONTACTS CRIMP OR PC TAIL TERMINATION Supplied with Size #23 Gold- Plated Copper Alloy Crimp, PCB, or Solder Cup Environmentally Sealed Series 801 High-Speed Plug and Receptacle Connectors The 801 Series is ideal for use in USB 2.0, esata and other high-speed databus applications. The connector is equipped with special PFA (Teflon) insulators and is optimized for use with high-speed differential wire such as our Series cable. Three insert arrangements are offered with 4, 7 and 10 size #23 contacts. The high-density, small form factor connector is suited for applications where traditional military circular connectors are too large or too heavy. The double-start threads provide full mating in 1½ turns, and the plug features an anti-decoupling spring for vibration resistance. The unique integral molding/band platform allows direct shield attachment and cable overmolding. Receptacles are available with printed circuit board contacts. Plugs have anti-decoupling wave spring, or specify ratchet mechanism for added security. Performance Impedance VSWR 100 OHMS ±7 OHMS at 100-Picosecond <1.4 up to 4-GHz In order to achieve high speed performance, this Connector must be mated to another high speed Connector. Data taken with adjacent pairs and grommet removed. Please consult factory for impedance and VSWR measurements with grommets intact. Insertion Loss 1 GHz.51 db 2 GHz.53 db 3 GHz.57 db 4 GHz 1.2 db 5 GHz 1.25 db Data taken with adjacent pairs and grommet removed. Please consult factory for insertion loss measurements with grommets intact. 14

17 Series 801 High-Speed Double-Start ACME Thread Connectors General information Series 801 Specifications Current Rating 5 AMPS Dielectric Withstanding Voltage 500 VAC RMS Insulation Resistance 5000 megohms minimum Operating Temperature -65 C. to +150 C. Shock 300 g. Vibration 37 g. Shielding Effectiveness 55 db minimum from 100MHz to 1000MHz. Durability 2000 mating cycles Materials and Finishes Double-Start ACME Threads resist cross-threading and shearing.these aerospace-grade Series 801 plugs feature 1½ turns of the coupling nut to full mating. Two Shell Styles: Integral platform for direct shield attachment using Band-Master ATS advanced termination system, or accessory thread for attaching a strain relief. Crimp, Rear Release contact system, with #23 contacts. Shells, Jam Nuts Insulators Contact Retention Clip Interfacial Seal, O-rings, Wire Sealing Grommet Aluminum alloy or stainless steel Copper alloy, 50 μinch gold plated PFA Beryllium copper alloy Fluorosilicone rubber Insert Arrangements Mating Face View of Pin Connector (Socket Connector Numbers are Reversed) Printed Circuit Board and Solder Cup versions with precision machined low profile shells. Shell Size 6 4 Size #23 Shell Size 6 7 Size #23 Shell Size 7 10 Size #23 Harsh Environment: fluorosilicone seals, aluminum or stainless steel shells, and gold-plated copper alloy contacts for superior performance in demanding applications. : Special purpose PFA (Teflon) insulators deliver superior Impedence, VSWR and insertion loss values. 15

18 Series and Series 801 High-Speed Double-Start ACME Threads Plug Connector Ordering Information Series 801 Plug Connector Glenair s Series 801 connector features a double-start modified stub ACME mating thread for improved protection against cross-mating and theread damage. Connector shells are machined aluminum or stainless steel. The connector is equipped with special PFA (Teflon) insulators and is optimized for use with high-speed differential wire such as our cable. Three insert arrangements are offered with 4, 7 and 10 #23 AWG contacts, packaged separately. Terminate contacts with standard M22520 tools. Metal clips inside the connector body lock contact into place. are removable. Fluorosilicone seals and rear grommet protect connector from water ingress. Terminate cable shield directly to connector body with BAND-IT strap, or choose rear accessory thread to attach optional cable clamp or backshell. HOW TO ORDER Sample Part Number M 7-10 P A Series Shell Style Shell Material / Finish Shell Size- Insert Arrangement Contact Type Shell Key Position Banding Platform Rear Accessory Thread -16 Plug with Anti- Decoupling Spring -26 Self-Locking Plug with Ratchet Mechanism (the "Clicker") M Aluminum / Electroless Nickel RoHS Compliant NF Aluminum / Cadmium with Olive Drab Chromate ZNU Aluminum / Zinc-Nickel with Black Chromate MT Aluminum / Nickel-PTFE RoHS Compliant Z1 Stainless Steel / Passivated RoHS Compliant Connector supplied with contacts A Pin Connector, Less B Socket Connector, Less P Pin S Socket G Pin with 30 AWG Crimp Barrel H Socket with 30 AWG Crimp Barrel A Normal Alternate Key Positions: B C D E F Connectors with contacts are supplied with signal crimp contacts. These contacts are not installed. 16

19 and Series 801 High-Speed Double-Start ACME Threads Plug Connector Ordering Information Series SAFETY WIRE HOLES AT 180 SHIELD TERMINATION PLATFORM 1.000(25.4) MAX B THREAD.960 (24.4) MAX. B THREAD MASTER KEY ø C ø A STRAIGHT KNURL Integral Band Platform D THREAD Accessory Thread Material and Finish Dimensions Style 16 Style 26 Shell Ø A Ø A Ø C D Thread Size In. mm. In. mm. B Thread In. mm. UNEF-2A P-1L-2B P-1L-2B Plug Key Positions A B A B C B A D E F Plug Barrel, Coupling Nut: Aluminum Alloy or Stainless Steel Insulator: PFA Interfacial Seal, Grommet Seal: Fluorosilicone Contact: Copper Alloy, 50 Microinch Gold Plated per ATSM B 488, Type II, Code C, Class 1.25 ( Min THK), over a suitable underplate. Performance Impedence VSWR 100 OHMS ±7 OHMS at 100-Picosecond <1.4 up to 4-GHz In order to achieve high speed performance, this Connector must be mated to another high speed Mighty Mouse Connector. This Connector mates with all Quick Coupling High Density Receptacle Connectors with same polarization and opposite contact gender, ( through and through ) Insertion Loss 1 GHz.51 db 2 GHz.53 db 3 GHz.57 db 4 GHz 1.2 db 5 GHz 1.25 db Data taken with adjacent pairs and grommet removed. 17

20 Series and Series 801 High-Speed Double-Start ACME Threads Crimp Receptacle Connector Ordering Information In-Line Shell Style 01 Rear Panel Jam Nut Mount Shell Style 07 HOW TO ORDER Square Flange Mount Shell Style 02 Sample Part Number Z1 6-4 S A Series Shell Style Shell Material / Finish Shell Size- Insert Arrangement Contact Type Shell Key Position Receptacle with Banding Platform Receptacle with Accessory Thread -01 In-Line For Free-Hanging Cables -02 Square Flange For Front or Rear Mounting M Aluminum / Electroless Nickel RoHS Compliant NF Aluminum / Cadmium with Olive Drab Chromate ZNU Aluminum / Zinc-Nickel with Black Chromate MT Aluminum / Nickel-PTFE RoHS Compliant Z1 Stainless Steel / Passivated RoHS Compliant Connector supplied with contacts A Pin Connector, Less B Socket Connector, Less P Pin S Socket G Pin with 30 AWG Crimp Barrel H Socket with 30 AWG Crimp Barrel A Normal Alternate Key Positions: B C D E F -07 Jam Nut For Rear Panel Mounting Connectors with contacts are supplied with signal crimp contacts. These contacts are not installed. 18

21 and Series 801 High-Speed Double-Start ACME Threads -01 In-Line Crimp Receptacle Dimensions Series 801 MASTER KEYWAY ø A.060 (1.5).900 (22.9) MAX.430 (10.9) MAX ø D B FLAT C THREAD RED FULL MATE INDICATOR STRIPE Integral Band Platform Accessory Thread E THREAD Dimensions Key Positions Shell Ø A B Flat C Ø D E Thread Size In. mm. In. mm. Thread In. mm. UNEF-2A P-.1L-2A P-1L2A A B Performance Impedence VSWR 100 OHMS ±7 OHMS at 100-Picosecond <1.4 up to 4-GHz In order to achieve high speed performance, this Connector must be mated to another high speed Connector. This Connector mates with all Quick Coupling High Density Plug Connectors with same polarization and opposite contact gender, ( , and and ). Insertion Loss 1 GHz.51 db 2 GHz.53 db 3 GHz.57 db 4 GHz 1.2 db 5 GHz 1.25 db Data taken with adjacent pairs and grommet removed. A B A B C D E F Material and Finish Plug Barrel, Coupling Nut: Aluminum Alloy or Stainless Steel Insulator: PFA Interfacial Seal, Grommet Seal: Fluorosilicone Contact: Copper Alloy, 50 Microinch Gold Plated per ATSM B 488, Type II, Code C, Class 1.25 ( Min THK), over a suitable underplate. 19

22 Series and Series 801 High-Speed Double-Start ACME Threads -02 Square Flange Receptacle Dimensions B BSC TYP MASTER KEYWAY ø C.060 (1.5).900 (22.9) MAX.430 (10.9) MAX A SQ TYP X ø D THRU ø F E THREAD RED FULL MATE INDICATOR BAND.100 (2.54) MAX PANEL THICKNESS G THREAD Integral Band Platform Accessory Thread Dimensions Ø D Shell A B BSC Ø C In. mm. E Ø F G Thread Size In. mm. In. mm. In. mm Thread In. mm. UNEF-2A P-.1L-2A P-1L-2A Series 801 Panel Cutout Key Positions ø C ±.003 (0.08) Performance Impedence VSWR ø A B BSC Shell Size 100 OHMS ±7 OHMS at 100-Picosecond <1.4 up to 4-GHz In order to achieve high speed performance, this Connector must be mated to another high speed Connector. This Connector mates with all Quick Coupling High Density Plug Connectors with same polarization and opposite contact gender, ( , and and ). Ø A Ø B Ø C In mm. In mm. In Insertion Loss mm GHz.51 db 2 GHz.53 db 3 GHz.57 db 4 GHz 1.2 db 5 GHz 1.25 db Data taken with adjacent pairs and grommet removed. A B A B A B C D E F Material and Finish Plug Barrel, Coupling Nut: Aluminum Alloy or Stainless Steel Insulator: PFA Interfacial Seal, Grommet Seal: Fluorosilicone Contact: Copper Alloy, 50 Microinch Gold Plated per ATSM B 488, Type II, Code C, Class 1.25 ( Min THK), over a suitable underplate. 20

23 and Series 801 High-Speed Double-Start ACME Threads -07 Jam Nut Receptacle Dimensions Series 801 MASTER KEYWAY ø A (26.9) MAX.060 (1.5).430 (10.9) MAX.100(2.54) MAX PANEL THICKNESS B FLAT ø F C FLAT D THREAD RED FULL MATE INDICATOR BAND E THREAD G THREAD Integral Band Platform Accessory Thread Dimensions Shell Ø A B Flat C Flat D E Thread Ø F G Thread Size In. mm. In. mm. In. mm. Thread UN-2A In. mm. UN-2A P-.1L-2A P-1L2A Series 801 Jam Nut Panel Cutout Key Positions A FLAT ø B Performance Impedence VSWR Shell Size 100 OHMS ±7 OHMS at 100-Picosecond <1.4 up to 4-GHz In order to achieve high speed performance, this Connector must be mated to another high speed Connector. This Connector mates with all Quick Coupling High Density Plug Connectors with same polarization and opposite contact gender, ( , and and ). In. ±.002 A Flat mm. ± 0.05 In. ±.002 Ø B mm. ± Insertion Loss 1 GHz.51 db 2 GHz.53 db 3 GHz.57 db 4 GHz 1.2 db 5 GHz 1.25 db Data taken with adjacent pairs and grommet removed. A B A B A B C D E F Material and Finish Plug Barrel, Coupling Nut: Aluminum Alloy or Stainless Steel Insulator: PFA Interfacial Seal, Grommet Seal: Fluorosilicone Contact: Copper Alloy, 50 Microinch Gold Plated per ATSM B 488, Type II, Code C, Class 1.25 ( Min THK), over a suitable underplate. 21

24 Series Series 801 High-Speed Double-Start ACME Threads PCB Receptacle Ordering Information Printed Circuit Board Receptacles feature low profile shells for minimum protrusion inside enclosures and integral standoffs for board washout. The connector is equipped with special PFA (Teflon) insulators and is optimized for use with high-speed differential wire such as our Series cable. Three insert arrangements are offered with 4, 7 and 10 PC tail or solder cup terminations. are non-removable. Series 801 Printed Circuit Board Receptacle Water Immersion, Unmated Specify connectors for applications where open face water immersion is not a requirement. For MIL-STD-810 Method 512G immersion requirements, specify watertight connectors. These connectors are specially sealed ("MOD-518") and are 100% tested to maintain a helium leak rate of 1 x 10-4 cc/second at one atmosphere pressure differential from -40C to +70C. HOW TO ORDER Sample Part Number M 7-10 P A Series Shell Style Shell Material / Finish Shell Size- Insert Arrangement Contact Type Key Position Receptacle for PCB or Solder Cup Termination, with Standard Epoxy Potting Receptacle for Solder Cup or PCB Termination with Special Mod Code 518 Sealing for Open Face (Unmated) Water Immersion Requirements. 100% Leak Tested. -02 Square Flange -07 Jam Nut M Aluminum / Electroless Nickel RoHS Compliant NF Aluminum / Cadmium with Olive Drab Chromate ZNU Aluminum / Zinc-Nickel with Black Chromate MT Aluminum / Nickel-PTFE RoHS Compliant Z1 Stainless Steel / Passivated RoHS Compliant P Pin, PC Tail S Socket, PC Tail E Pin, Solder Cup F Socket, Solder Cup A Normal Alternate Key Positions: B C D E F Performance Impedence VSWR 100 OHMS ±7 OHMS at 100-Picosecond <1.4 up to 4-GHz In order to achieve high speed performance, this Connector must be mated to another high speed Connector. This Connector mates with all Quick Coupling High Density Plug Connectors with same polarization and opposite contact gender, ( , and and ). Insertion Loss 1 GHz.51 db 2 GHz.53 db 3 GHz.57 db 4 GHz 1.2 db 5 GHz 1.25 db Data taken with adjacent pairs and grommet removed. Material and Finish Plug Barrel, Coupling Nut: Aluminum Alloy or Stainless Steel Insulator: PFA Potting Compound: Epoxy Interfacial Seal, Grommet Seal: Fluorosilicone Contact: Copper Alloy/Gold Plate 22

25 Series 801 High-Speed Double-Start ACME Threads -02 Square Flange and -07 Jam Nut Dimensions Series 801 H BSC TYP ø J.060 (1.5).760 (19.3) MAX.280 (7.1) MAX.125 (3.18) MIN PC TAIL MASTER KEYWAY.925 (23.5) MAX.060 (1.5).100 (2.54) MAX PANEL THICKNESS.280 (7.1) MAX.125 (3.18) MIN PC TAIL G SQ TYP ø L ø F B FLAT ø L ø F Shell Size D THD 4X ø K THRU Square Flange Dimensions Ø K E Ø A B Flat C Flat D Thread Ø F G Sq. H BSC Ø J In. mm. In. mm. In. mm. In. mm. Thread UN-2A In. mm. In. mm. In. mm. In. mm. ±.003 ± P-.1L-2A # P-1L2A ø A ø C ±.003 (0.08) B BSC D FLAT 02 Square Flange 07 Jam Nut c L.038 (0.97) TYP 1 2 c L Pin Connector (0.97) TYP ø E.025 RED FULL MATE INDICATOR BAND Shell Size Pin Connector 6-7 ø A Straight PCB Footprints C FLAT Jam Nut Panel Cutout Ø A Ø B Ø C In. mm. In. mm. In. mm..025 E THREAD RED FULL MATE INDICATOR BAND D THREAD In. ±.002 D Flat mm. ± 0.05 In. ±.002 Ø L Tail Dia..018/.022 (0.46/0.56) Ø E mm. ± (0.97) TYP.076 (1.93) TYP c L c L (1.68) TYP Pin Connector 7-10 c L.114 (2.90).038 (0.97) TYP c L.076 (1.93) TYP (1.68) TYP c L.038 (0.97) TYP 2 1 c L Socket Connector (0.97) TYP Socket Connector (0.97) TYP.076 (1.93) TYP c L 2 1 c L (1.68) TYP Socket Connector (2.90).038 (0.97) TYP.076 (1.93) TYP c L c L (1.68) TYP 23

26 Series 801 Overmolded Differential Pair Cordsets Series 801 Double-Start ACME Thread Abrasion-Resistant Polyurethane Jacket provides cold temperature flexibility and high strength. Low smoke/zero halogen material meets requirements for low toxicity. 90% Coverage Silver Plated Copper Braid is terminated directly to connector with stainless steel Band-Master ATS strap. Watertight Overmold provides strain relief and environmental protection. Overmolded Differential Cordset 100 Ohm Differential Parallel Pair Cable provides outstanding performance and durability. Series Ohm Differential Parallel Pair Harsh Environment Shielded Cordsets These overmolded cordsets withstand abrasion and chemical exposure. Low smoke zero halogen jacket reduces the amount of toxic and corrosive gasses emitted during combustion. Cable construction features silver coated stranded conductors with extruded foamed fluoropolymer insulation, silver plated copper braid shield and extruded FEP jacket. Choose single-ended pigtails or double-ended "back-to-back" versions. These cables are ideally suited for high speed digital signals such as SATA or other applications that require 100 ohm controlled impedance performance. Semi-rigid polyamide overmold provides strain relief and environmental sealing. HARSH ENVIRONMENT CORDSET SPECIFICATIONS Cable Jacket Material Thermoplastic Polyurethane, Black, Low-Smoke, Zero-Halogen Cable Shield Silver-Coated Copper Braid, 90% Minimum Coverage Conductors Silver Coated Stranded Wire, PTFE Insulated Band-Master ATS Shield Termination Band Stainless Steel Current Rating #23 1 Amp Test Voltage (Dielectric Withstanding Voltage) # VAC Sea Level Insulation Resistance 200 megohms minimum Operating Temperature -30 C. to +150 C. Solvent Resistance, Polyamide Overmold Excellent Resistance to Most Solvents, Fuels, and Oils; Poor Resistance to Strong Acids and Bipolar Solvents (Alcohol) Shielding Effectiveness 50 db minimum from 100MHz to 1000MHz. Toxicity Index 3.9 per NES 713 Cable jacket Flammability and Toxicity Oxygen Index 28% per ASTM D-2863 Smoke Index 24 per NES

27 Series 801 High-Speed 100 OHM Differential Parallel Pair Data Cable Series 801 Construction Details Conductor Insulation Inner Shield Outer Shield Jacket 28 AWG Silver Plated High Strength Copper Alloy Extruded Foamed Fluoropolymer Color: Blue and White Aluminum/Polyester Tape, 100% Coverage Round Silver Plated Copper Braid, 90% Coverage Extruded FEP Color: Transparent Blue.113 (2.9).097 (2.5) Conductor Insulation Inner Shield.075 (1.9).015 (0.4).059 (1.5) Outer Shield 2x.038 (1.0) Jacket Properties Impedance 100 ± 10 Ohms Capacitance 12.0 pf/ft (Nom) V.O.P. 80% Attenuation Temperature Rating MHz MHz MHz 150 C 25

28 Series and Overmolded Differential Pair Cordsets Series 801 Double-Start ACME Thread 2 PAIR DIFFERENTIAL HIGH SPEED OVERMOLDED CORDSET Sample Part Number A C 4 M 6-4 N A -36 Series End A Connector End B Connector Wire Size Shell Material / Finish Insert Arr. Protective Cover Shell Key Pos. Length Overmolded Cordset, with size #23 -A Plug, with Male Pin -B Plug, with Female Socket -C Receptacle, with Male Pin -D Receptacle, with Female Socket A Plug, with Male Pin B Plug, with Female Socket C Receptacle, with Male Pin D Receptacle, with Female Socket N No Connector (Single-Ended) 4 #28 AWG M Aluminum / Electroless Nickel NF Aluminum / Cadmium with Olive Drab Chromate ZNU Aluminum / Zinc- Nickel with Black Chromate MT Aluminum / Nickel- PTFE Z1 Stainless Steel / Passivated 6-4 P Metal Protective Covers Included N No Covers Supplied A Normal B Pos. B C Pos. C D Pos. D E Pos. E F Pos. F Overall Length In Inches 12 Inch Min. 3 PAIR DIFFERENTIAL HIGH SPEED OVERMOLDED CORDSET Sample Part Number A C 6 M 6-7 N A -36 Series End A Connector End B Connector Wire Size Shell Material / Finish Insert Arr. Protective Cover Shell Key Pos. Length Overmolded Cordset, with size #23 -A Plug, with Male Pin -B Plug, with Female Socket -C Receptacle, with Male Pin -D Receptacle, with Female Socket A Plug, with Male Pin B Plug, with Female Socket C Receptacle, with Male Pin D Receptacle, with Female Socket N No Connector (Single-Ended) 6 #28 AWG M Aluminum / Electroless Nickel NF Aluminum / Cadmium with Olive Drab Chromate ZNU Aluminum / Zinc- Nickel with Black Chromate MT Aluminum / Nickel- PTFE Z1 Stainless Steel / Passivated 6-7 P Metal Protective Covers Included N No Covers Supplied A Normal B Pos. B C Pos. C D Pos. D E Pos. E F Pos. F Overall Length In Inches 12 Inch Min. Contact factory for wiring schematics 26

29 and (SATA) Overmolded Differential Pair Cordsets Series 801 Double-Start ACME Thread Series PAIR DIFFERENTIAL HIGH SPEED OVERMOLDED CORDSET Sample Part Number C D 8 Z P A -72 Series End A Connector End B Connector Wire Size Shell Material / Finish Insert Arr. Protective Cover Shell Key Pos. Length Overmolded Cordset, with Size #23 -A Plug, with Male Pin -B Plug, with Female Socket -C Receptacle, with Male Pin -D Receptacle, with Female Socket A Plug, with Male Pin B Plug, with Female Socket C Receptacle, with Male Pin D Receptacle, with Female Socket N No Connector (Single-Ended) 8 #28 AWG M Aluminum / Electroless Nickel NF Aluminum / Cadmium with Olive Drab Chromate ZNU Aluminum / Zinc- Nickel with Black Chromate MT Aluminum / Nickel- PTFE Z1 Stainless Steel / Passivated 7-10 P Metal Protective Covers Included N No Covers Supplied A Normal B Pos. B C Pos. C D Pos. D E Pos. E F Pos. F Overall Length In Inches 12 Inch Min. OVERMOLDED SATA CORDSET Sample Part Number B N 4 NF 6-7 N A -48 Series End A Connector End B Connector Wire Size Shell Material / Finish Insert Arr. Protective Cover Shell Key Pos. Length Overmolded Cordset, with Size #23 -A Plug, with Male Pin -B Plug, with Female Socket -C Receptacle, with Male Pin -D Receptacle, with Female Socket A Plug, with Male Pin B Plug, with Female Socket C Receptacle, with Male Pin D Receptacle, with Female Socket N No Connector (Single-Ended) 4 #28 AWG M Aluminum / Electroless Nickel NF Aluminum / Cadmium with Olive Drab Chromate ZNU Aluminum / Zinc- Nickel with Black Chromate MT Aluminum / Nickel- PTFE Z1 Stainless Steel / Passivated 6-7 P Metal Protective Covers Included N No Covers Supplied A Normal B Pos. B C Pos. C D Pos. D E Pos. E F Pos. F Overall Length In Inches 12 Inch Min. Contact factory for wiring schematics 27

30 Series 801 Series 801 Double-Start ACME Threads Overmolded Cordset Dimensions A MAX. LENGTH + 2.0/-0.0 (+50.8/ -0.0) 12 IN. (300 mm.) MIN. B MAX. POLYAMIDE OVERMOLD SHIELDED JACKETED CABLE SERIES 801 RECEPTACLE OPTIONAL PROTECTIVE COVER WITH POLYURETHANE WIRE ROPE RIGHT ANGLE CORDSETS E MAX. C MAX. LENGTH + 2.0/-0.0 (+50.8/ -0.0) 12 IN. (300 mm.) MIN. MASTER KEY LOCATED 180 FROM CABLE EXIT D MAX. How To Order Right Angle Cordsets Insert the letter R after the End A or End B Connector letter designator. Example Straight cable 801-xxx-AC4Z16-4PA-72 Right Angle 801-xxx-ARCR4Z16-4PA-72 DIMENSIONS Shell A Max. B Max. C Max. D Max. E Max. Size In. mm. In. mm. In. mm. In. mm. In. mm

31 and Series 801 Double-Start ACME Threads Metal Protective Cover Ordering Information Series 801 Protect Connectors From Damage Machined aluminum covers have rubber gaskets for a watertight fit. Stainless Steel Fittings and Rings Choose small diameter eye fittings for panel attachment. Larger rings fit under the jam nut or over cable jackets. Split rings can be installed on fully assembled cables. Polyurethane-Coated SST Wire Rope offers high strength, excellent abrasion resistance and good flexibility. Or, choose Teflon jacket for high temperature exposure. Braided Nylon Rope provides excellent flexibility and good abrasion resistance, and can be ordered with slip knot fittings for easy installation on any size cable. HOW TO ORDER Sample Part Number M -G Series Shell Material / Finish Attachment Type Shell Size Attachment Code Attachment Length in Inches Protective Cover for use with Series 801 Plugs Protective Cover for use with Series 801 Receptacles M Aluminum / Electroless Nickel RoHS Compliant NF Aluminum / Cadmium with Olive Drab Chromate ZNU Aluminum / Zinc-Nickel with Black Chromate MT Aluminum / Nickel-PTFE RoHS Compliant Z1 Stainless Steel / Passivated RoHS Compliant -G Nylon Rope -H SST Wire Rope, Tefl on Jacket -N No Attachment -S SST Sash Chain -SK Nylon Rope With Slip Knot -T SST Wire Rope, No Jacket -U SST Wire Rope, Polyurethane Jacket "SST" = Stainless Steel 6 7 Omit for attachment Types N (No Attachment) and SK (Slip Knot) Small Ring Large Ring Split Ring (3.20) I.D (3.68) I.D (4.78) I.D (5.00) I.D (9.78) I.D (11.30) I.D (14.48) I.D (16.13) I.D (17.65) I.D (22.48) I.D (27.17) I.D (28.83) I.D (30.73) I.D (32.39) I.D (34.94) I.D (10.67) I.D (12.19) I.D (16.13) I.D (18.92) I.D (22.48) I.D (25.65) I.D (28.58) I.D (34.16) I.D. Omit for attachment Type N (No Attachment) Example "-6" equals six inch length 29

32 Series and Series 801 Double-Start ACME Threads Metal Protective Cover Dimensions Attaching a Receptacle Cover to a Rear Panel Mounted Jam Nut Receptacle ATTACHMENT RING FITS UNDER JAM NUT PROTECTIVE COVER PANEL RECEPTACLE CONNECTOR STYLE 07 Attaching a Cover to a Panel With a Screw JAM NUT Solid Ring Ring I.D. Ring O.D. Dia. Shell In. mm. In. mm. Code Size ±.010 ±0.25 ±.015 ± , Attaching a Cover to a Cable Assembly With a Solid Ring Small Ring for Attaching Receptacle Covers to a Panel with a Screw Ring I.D. Ring O.D. Dia. Screw In. mm. In. mm. Code Size ±.005 ±0.13 Max. Max. 01 #4, M # #8, M # Attaching a Cover to a Cable Using a Split Ring INSTALL RING BEFORE MOLDING OR BACKSHELL INSTALLATION INSTALL SPLIT RING OVER CABLE JACKET #4-40 FILL. HD. SCREW #4-40 LOCKNUT AND SPLIT WASHER Solid Ring Dia. Code Ring I.D. Ring O.D. In. mm. In. mm. ±.010 ±0.25 ±.015 ± 0.38 Shell Size 14 5, , , , Large Split Ring for Attaching Covers to Cables Dia. Code Max. Cable Dia. (in.) Ring Diameter Min. ID Max. OD In. mm. In. mm

33 and Series 801 Double-Start ACME Threads Metal Protective Cover Dimensions Series 801 GASKET.800 (20.3) MAX.800 (20.3) MAX GASKET.600 (15.2) MAX A B C THREAD -2A LENGTH ±.25 (6.4) C THREAD -2B LENGTH ±.25 (6.4) Plug Cover Receptacle Cover Dimensions Shell A Max. B Max. Size In. mm. In. mm. C P-1L P-1L Nylon Rope Lanyard Options -55 to +100 C., black, very fl exible, very good abrasion resistance, good resistance to fuels,.120" (3mm) diameter Polyurethane Coated Wire Rope Black polyurethane over stainless steel rope, -55 to +125 C., very flexible, excellent abrasion resistance, excellent resistance to fuels,.080" (2mm) diameter Materials and Finishes Cover Aluminum alloy or stainless steel Gasket Silicone rubber Wire,Hardware Stainless steel, passivated Teflon Jacketed Wire Rope Sash Chain Slip Knot (SK) for Attaching Covers to Cable Translucent FEP jacket over stainless steel, -55 to +200 C., fair fl exibility, good abrasion resistance,.100" diameter Stainless steel, #8 chain,.240" (6mm) 55 to +100 C., black, very flexible, very good abrasion resistance, good resistance to fuels,.120" (3mm) diameter. Length includes.5" (13mm) diameter loop. 31

34 Series and Series 801 Double-Start ACME Threads Rubber Protective Cover Ordering Information These splashproof molded rubber covers fit all Series 801 plugs and receptacles. Braided black nylon lanyard is available with metal rings, cable tie or slipknot for attachment to panel or to cable to C operating temperature, fungus resistant per MIL-STD-810G Method Materials Cover Neoprene rubber blend, black Lanyard.062" (1.57) diameter nylon cord, black Cable Tie 6/6 nylon, black, SST locking tab Ring Stainless steel, black zinc-cobalt fi nish Crimp Sleeve Copper Alloy, black zinc-cobalt fi nish HOW TO ORDER Sample Part Number G 6 - SCS C Series Shell Size Lanyard Type Lanyard Length Attachment Code Conductive Rubber Protective Cover for use with Series 801 Receptacles G Nylon Rope (Omit for no lanyard) Length in Inches -WS Nylon Cable Tie, 1.77 Inch (45mm) Maximum Wire Bundle Diameter -SCS Adjustable Slip Knot with Crimp Sleeve. The sleeve can be crimped with pliers for a permanent attachment. -00 Lanyard With No Attachment (Fused End) Lug Terminals and Rings Omit for Standard Neoprene C Conductive Rubber Protective Cover for use with Series 801 Plugs Lug Terminal Solid Ring (3.20) I.D (3.68) I.D (4.78) I.D (5.00) I.D (9.78) I.D (11.30) I.D (13.11) I.D (14.48) I.D (14.81) I.D (16.13) I.D (17.65) I.D (19.71) I.D (22.48) I.D (25.76) I.D (25.78) I.D (27.18) I.D (28.83) I.D (28.98) I.D. 32

35 and Series 801 Double-Start ACME Threads Rubber Protective Cover Dimensions Series 801 Attaching a Receptacle Cover to a Rear Panel Mounted Jam Nut Receptacle Attaching a Cover to a Panel With a Screw ATTACHMENT RING FITS UNDER JAM NUT PROTECTIVE COVER PANEL RECEPTACLE CONNECTOR STYLE 07 LUG TERMINAL SCREW CONNECTOR JAM NUT Solid Ring Dia. Code Shell Size Ring I.D. Ring O.D. In. mm. In. mm. ±.010 ±0.25 ±.015 ± Lug Terminal for Attaching Receptacle Covers to a Panel with a Screw PROTECTIVE COVER Ring I.D. Ring O.D. Dia. Screw In. mm. In. mm. Code Size ±.005 ±0.13 Max. Max. 01 #4, M # #8, M # Attaching a Cover to a Cable Assembly With Type WS Cable Tie Attaching a Cover to a Cable Assembly With a Solid Ring BLACK NYLON CABLE TIE WITH SST LOCKING TAB INSTALL RING BEFORE MOLDING OR BACKSHELL INSTALLATION SST SCREW WITH SELF-LOCKING NUT Attaching a Cover to a Cable Assembly With Type SCS Slip Knot Dia. Code Shell Size Ring I.D. Ring O.D. In. mm. In. mm. ±.010 ±0.25 ±.015 ± FRICTION/CRIMP SLEEVE Large Ring

36 Series and Series 801 Double-Start ACME Threads Rubber Protective Cover Dimensions SOLID RING ø A LUG TERMINAL NO LUG, FUSED END (00) SLIP KNOT WITH CRIMP SLEEVE (SCS) ø.50 REF LENGTH MEASURED AT.50 DIAMETER ø B CABLE TIE (WS) C D LENGTH (SEE PART NUMBER DEVELOPMENT) Receptacle Cover Shell Ø A Ø B C D Size In. mm. In. mm. In. mm. In. mm Plug Cover Shell Ø A Ø B C D Size In. mm. In. mm. In. mm. In. mm

37 MORE HIGH SPEED MATCHED IMPEDANCE SOLUTIONS FROM GLENAIR The world's broadest selection of high-speed, high-bandwidth in ter con nect products for milaero and other harsh environment applications Glenair offers a full range of products to solve the most demanding high-speed interconnect challenges from the size- and weight-saving line, to Fiber Optic solutions that address the most demanding high bandwidth and EMI immunity requirements. Many Glenair connector technologies that are suitable for general purpose signal applications also excel in 100 Ohm high-speed differential impedance applications as well as other installations that require low insertion loss, low VSWR and high data-rate performance. These pages present brief overviews of the interconnection systems produced by Glenair capable of delivering benchmarked high-speed performance. Please view these catalogs on our website for additional information Series 80 Connectors and Cables Glenair s revolutionary connector series that reduces interconnect system size and weight by 50% compared to MIL-DTL connectors. Originally developed as a smaller and lighter alternative to D38999 connectors for aerospace e applications, the is used on hundreds of missioncritical defense, medical, industrial and geophysical applications. The product line includes filtered connectors, power and coaxial layouts, board mount connectors, overmolded cordsets, plus fiber optic and high-speed versions. High-speed cordsets, terminated to a broad range of commercial USB and Ethernet interconnects are available as standard catalog offerings. MIL-DTL Micro-D Connectors and Cables Glenair offers both Military Standard Micro-D connectors as well as COTS selections, backshells, mounting hardware and more. Our TwistPin contact provides superior performance especially in vibration and shock applications. Where interconnect failure is simply not an option, the Glenair high-reliability Micro-D offers a wealth of performance benefits which far outweigh any potential cost savings realized by specifying a lesser caliber connector. If downtime is a critical concern, other connectors cannot match the long-term durability and performance advantages of the MIL-DTL Micro-D.

38 Fiber Optic Interconnect Solutions Today, the use of fiber optic systems to carry digitized voice, video, and data is universal. Fiber optic interconnect systems offer exponentially larger bandwidth compared to standard electrical cabling. Glenair manufactures a solution for every branch of the military and every mission-critical commercial application. Glenair's fiber optic offerings include Series #16 AWG, QPL MIL-PRF fiber optic connectors and MIL-DTL type solutions, the innovative high-density GHD connector system, and the revolutionary Eye-Beam expandedbeam lens terminus. The low insertion loss Eye-Beam offers comparable performance to standard butt joint termini in a package that s built to withstand rugged use and frequent mating/de-mating in n field conditions. AS39029 Qualified High Performance $6 43/ DQG *OHQDLU &RPPHUFLDO +LJK 3HUIRUPDQFH WV &RQQHFWRU &RQWDFWV 8QLWHG 6WDWHV 8QLWHG.LQJGRP *HUPDQ\ )UDQFH 1RUGLF )LUVW (GLWLRQ -DQXDU\,WDO\ 6SDLQ -DSDQ Glenair brings a new perspective to the supply of high-performance crimp, shielded and fiber optic contacts: High Availability! Whether you need a standard duty socket for a MIL-DTL connector or an extended duty pin for MILDTL Series III, we have you covered with products that are always in stock with no dollar or quantity minimums. The AS39029 product series supplied by Glenair includes all the most popular standard and extended duty pin and socket co contacts for use in high-performance circular and rectangular on multi-pin connectors. We are particularly well positioned to supply mullti special-purpose shielded Coaxial, Twinax and Quadrax s contacts. High-Speed Datalink Transmission Connectors Bridge the gap between high performance data transmission and rugged field-ready circular connectors with Glenair Datalink Transmission Connectors: High-speed serial data connectors and standard duty Ethernet connectors protected with military-grade connector shell packaging. USB, RJ-45 and Quadrax interconnects are integrated inside sealed, ruggedized M5015 and M26482 type connector shells. By integrating the two into o a single, refined package, users will no longer have to worry about damaging delicate high bandwidth connections in harsh conditions. The MIL-DTL-5015 or MIL-DTL type connector shells provide impact resistance, ingress protection and positive coupling all in a wide array of finishes and shell styles. +LJK 6SHHG ³'DWD/LQN +L L N 7 UD 7UDQVPLVVLRQ &RQQHFWRUV 86% 5- DQG 4XDGUD[,QWHUFRQQHFWV LQ 6HDOHG 86% 4 5 XJJ JHGL]HG 0 DQG 0 7\SH 3DFNDJLQJ 5XJJHGL]HG 0 DQG 0 7\SH 3DFNDJLQJ 8 Q L W H G Q L W H G 6 W D W H V 8 G 6 W D W H V 8 Q L W H G. L Q J G R P * H U P D Q \ H U P D Q \ ) ) U D Q F H 1 R U G L F F,, W D O \ W D O \ 6 6 S D L Q -DSDQ

39 United States United Kingdom Germany France Nordic Italy Spain Japan Series 79 Micro-Crimp Connectors Today's defense/aerospace systems require advanced levels of environmental protection, electromagnetic shielding and size/weight reduction. The Series 79 was developed to meet these needs, especially for applications that require higher-density, smaller size and lighter weight than is provided by the venerable D-sub. The Micro-Crimp connector features crimp, rear-release size #23 contacts on.075 inch (1.9 mm) spacing, as well as size #12 and #16 power and coaxial crimp contacts in a range of hybrid layouts. Panel mounted connectors feature conductive sealing gaskets. Right angle printed circuit board connectors have an EMI shroud to prevent electromagnetic interference. Wire sealing grommets and interfacial seals protect circuits from moisture and contamination. Available in 31 insert arrangements, the Micro-Crimp provides a wide selection of arrangements for highspeed data as well as general-duty signal and power transmission. MIL-DTL Cylindrical Connectors Hermetics, Filters, Environmentals, Feed- ed- Thrus, Lanyards, Sav-Cons and More! 1st Edition September, 2008 MIL-DTL Cylindrical Connectors MIL-DTL is a high-performance connector family designed for cableto-panel I/O applications in military aerospace and other demanding situations. Environmental class plugs and receptacles with highdensity insert arrangements (up to 128 contacts) are available with crimp removable contacts, PC tails, and solder cups. Glenair manufactures both Military Standard MIL-DTL as well as commercial Hermetic connectors plus EMI/EMP filter versions, standard environmentals, bulkhead feedthroughs, Sav-Con connector savers and more. All of our D38999 type solutions are available with contacts and insulators optimized for highspeed applications Series 28 HiPer-D Connectors Meet the Series 28 HiPer-D. Intermateable and intermountable with standard M24308 type D-Subs, the HiPer-D meets the need for improved performance in hostile environments. Unlike standard M24308 connectors with stamped steel shells, the HiPer-D is machined from aluminum or stainless steel. The dielectric inserts are made with thermoset epoxy for unbeatable resistance to chemicals and are capable of 200 C continuous operating temperature. Aerospace grade fluorosilicone grommets and face seals provide watertight sealing. Integrated grounding fingers provide advanced electromagnetic compatibility. Best of all, the HiPer-D is available in every standard and high-density M24308 layout and is stocked for immediate same-day shipment. Visit us at and use the literature order form for immediate catalog fulfillment

40 A World of Interconnect Solutions Glenair, Inc Air Way Glendale, California Telephone: Fax: Glenair Power Products Group 860 N. Main Street Extension Wallingford, CT Telephone: Facsimile: Glenair UK Ltd 40 Lower Oakham Way Oakham Business Park P.O. Box 37, Mansfi eld Notts, NG18 5BY England Telephone: Facsimile: Glenair Microway Systems 7000 North Lawndale Avenue Lincolnwood, IL Telephone: Facsimile: Glenair Nordic AB Gustav III : S Boulevard 46 S Solna Sweden Telephone: Facsimile: sales@glenair.se Glenair Electric GmbH Siemensstrasse 9 D Steinbach Germany Telephone: Facsimile: germany@glenair.com Glenair Iberica C/ La Vega, Velada Spain Telephone: Facsimile: sales@glenair.es Glenair Italia S.p.A. Via Cà dell Orbo Nord, Villanova di Castenaso Bologna, Italy Telephone: Facsimile: info@glenair.it Glenair France SARL 7, Avenue Parmentier Immeuble Central Parc # Toulouse France Telephone: Facsimile: sales@glenair.fr 2011 Glenair, Inc. Printed in U.S.A.

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